Meet Katherine O’Neal | CEO and Patternmaker

We had the good fortune of connecting with Katherine O’Neal and we’ve shared our conversation below.

Hi Katherine, can you walk us through the thought-process of starting your business?
While I was going through cancer treatment, I was laid off from my position at a global corporate manufacturer/retailer. Honestly, I’d already been working on a strategy to get out of there — it was all chaos all the time. They had recently brought in toxic, incompetent managers that made every day a grind. I knew I never wanted to be subjected to that kind of short-sighted “leadership” again. So when the layoff happened, my immediate thought was: “What can I do with this?”

Being laid off in the middle of cancer treatment was a kick in my pride, but I immediately recognized a golden opportunity. I’d already been through something similar during COVID in 2020. I’d been furloughed, and I pivoted to making masks and selling them to my community in the early days of the pandemic. Suddenly I was doubling my previous paycheck, and I thought, this self-employment thing really could work. That experience cemented one of my guiding beliefs: find ways to take the “worst” things that happen to you and turn them into opportunities that completely change your life for the better. When the next “worst case scenario” appeared in the form of lay-off curing cancer treatment, I already had a road map and leaned hard into that.

Within a month, I’d purchased apparel CAD software and was reaching out to industry contacts. The second person I called was Angela Ryberg of Tacos, Tequila, & Tech Design. We’d worked together at Halston back in 2012 and had become friends. She said, “Katherine, I quit my corporate job a year ago and have been freelancing ever since. I have so much work coming my way that I’m subcontracting every job — and my patternmaker is retiring. Please come work with me.” So the major pieces fell into place quickly.

Alright, so for those in our community who might not be familiar with your business, can you tell us more?
I run a patternmaking and technical design business that specializes in helping emerging brands navigate product development and connect with domestic manufacturers. My role serves as a bridge between creative vision and technical execution. We offer 2D patternmaking and 3D prototyping across a wide range of categories — from high-end bridal to budget-friendly juniors to sewn medical devices. We support brands from concept through production. I also bring the rare advantage of doing patternmaking, grading, and markers all within the same CAD system. This means there’s no loss of data, no translation errors between programs, and a much smoother experience for everyone involved. That’s a big part of what makes our workflow efficient and highly accurate, and it’s something I’m proud to offer.

Another point of pride is the way we facilitate domestic production. We help small brands connect to and engage with U.S. based manufacturers more successfully. We help those manufacturers grow by bringing them consistent, high-quality work. I believe in bringing as much of this industry back to the U.S. as possible, and if I can help build the infrastructure that makes that possible, that’s something I’ll hang my hat on.

One of the things that sets me apart is the breadth and depth of my experience. I’ve worked in nearly every part of the industry: tech design, fit, patternmaking, grading, marker-making, construction, and production. I understand the full product life cycle, and that gives me the ability to step in wherever a brand is and guide them forward with clarity and care. Whether someone’s launching their very first collection or troubleshooting production with a factory, I can meet them at their level.

The biggest lesson I’ve learned is that consistency will take you further than talent alone. I’m always learning, always improving, and always looking for ways to offer more value. I’ve built this business with integrity and intention — not overnight, but over years of showing up, doing the work, and developing a reputation people can rely on.

At the end of the day, I care about craftsmanship, connection, and contributing to something bigger than myself. My job isn’t just about executing patterns — it’s about creating structure, solving problems, and building trust across the process, all while being a steady hand in an often unpredictable industry. My end goal is always the same: to make things work better for everyone involved.

Let’s say your best friend was visiting the area and you wanted to show them the best time ever. Where would you take them? Give us a little itinerary – say it was a week long trip, where would you eat, drink, visit, hang out, etc.
Obviously I’d head straight to the fashion district and can spend all day there searching for the perfect fabric or components. It’s a must-visit for anyone interested in design or beautiful materials — always full of inspiration. I’d show them where I source special pieces, and we’d certainly leave with way more than we intended.

Grand Central Market downtown is vibrant, packed with great vendors, but still feels local and grounded. The Original Farmers Market at The Grove fits in the same vein – I prefer unpretentious atmosphere over the ritz and polish of other shopping districts.

For something a little more offbeat, I’d plan an urban hike through Laurel Canyon – walking past the places where legendary musicians lived and created. It’s like stepping into the history of rock and folk music, and the area still has a lingering creative electricity. Plus there’s nothing like those hills work your energy out.

Other favorite activities are line dancing and two-stepping at Cowboy Country in Long Beach. Taking a slow drive through Angeles National Forest, or Los Padres for a breath of wilderness is also at the top of my list. In my opinion, the best visits aren’t about cramming in a checklist. They’re about discovery and wandering.

Who else deserves some credit and recognition?
I also wouldn’t be where I am without the support of my family — not just emotionally, but in helping me access the tools I needed at key moments. They made it possible for me to pursue higher education. When I decided to invest in industry-standard CAD software to launch my business, they helped me make that leap. Their support gave me a foundation to keep learning, growing, and earn my place through hard work, curiosity, and consistency.

Mentors have also been essential in helping me to build my skills. There are too many to name them all, but Edie Ladd and Rosee Aranda are two industry connections who have recently been instrumental in helping me level-up.

Website: https://xyz-pattern.com/

Instagram: @xyz_pattern

Image Credits
GMC Photographer, Taboo Media